Photosensitive polymer and composition

ABSTRACT

A PHOTOSENSITIVE COMPOSITION COMPRISING A PHOTOSENSITIVE POLYMER CONTAINING AT LEAST ONE A,B-UNSATURATED CARBOXYLIC RADICAL OF THE FORMULA:   AR-(C(-Y)=C(-X))N-COO-   WHEREIN X AND Y, RESPECTIVELY, REPRESENT A HYDROGEN OR HALOGEN ATOM, OR A CYANO OR NITRO RADICAL; AR REPRESENTS AN ARYL RADICAL OR A SUBSTITUTED ARYL RADICAL; AND N REPRESENTS AN INTEGER OF FROM 1-2, WHICH IS OBTAINED BY REACTING A POLYMER CONTAINING AT LEAST ONE ACTIVE HALOGEN ATOM WITH A SALT OF AN A,B-UNSATURATED CARBOXYLIC ACID HAVING THE FORMULA:   AR-(C(-Y)=C(-X))N-COOH   WHEREIN THE DEFINITIONS OF X, Y, AR AND N ARE RESPECTIVELY MENTIONED ABOVE; AND A SOLVENT FOR SAID PHOTOSENSITIVE POLYMER.

U nited States Patent 3,817,876 PHOTOSENSITIVE POLYMER AND COMPOSITION Hideo Fukutani and Konoe Miura, Tokyo, Japan, as-

;ignors to Mitsubishi Chemical Industries, Ltd., Tokyo,

apan No Drawing. Filed Sept. 16, 1971, Ser. No. 181,188 Claims priority, appiligatitlnilJgpan, Sept. 16, 1970,

Int. Cl. co 23/22 US. Cl. 260-2 A 5 Claims ABSTRACT OF THE DISCLOSURE A photosensitive composition comprising a photosensitive polymer containing at least one a s-unsaturated carboxylic radical of the formula:

wherein the definitions of X, Y, Ar and n are respectively mentioned above; and a solvent for said photosensitive polymer.

BACKGROUND OF THE INVENTION Field of invention This invention relates to a photosensitive polymer and to a photosensitive composition containing said polymer. More particularly, this invention relates to a photosensitive polymer which may be used for preparing a photo-' resist or for photoengraving.

Description of prior art Photosensitive polymer compositions are commonly used as photoresists or for photoengraving in a myriad number of applications. For many applications it is required that the photosensitive composition used have a high degree of sensitivity, good resolving power, good aging stability, good heat resistance, good adhesiveness and good etchant resistance. It should also be easily exposed and should not contain certain types of impurities, such as metals, which could adversely afiect the properties of the resist or the properties of the object treated.

Polyvinylcinnamate containing photosensitive compositions are well known in the art, and widely used. This polymer is formed by reacting polyvinylalcohol with cinnamic acid. Its photosensitive composition is characterized, however, by low acid resistance and adhesiveness, and it cannot be applied to precious metals, certain glasses, silicone, germanium or ceramics. The range of application for this type of photosensitive composition is therefore limited.

Moreover, these compositions contain a significant amount of sodium, which can adversely afiect electrical properties, which renders the use of this type of composition unacceptable for those applications involving the formation of electrical parts.

It has been considered to prepare a photosensitive polymer by polymerizing an alkylene oxide having a cinnamic acid radical. This polymerization reaction, however, is somewhat abnormal in characteristics so that the polymer is difiicult to obtain.

31,817,876 Patented June 18, 1974 SUMMARY OF THE INVENTION Accordingly, it is one object of this invention to provide a photosensitive polymer and a photosensitive composition containing said polymer.

It is another object of this invention to provide a photosensitive polymer having an acceptable number of cinnamic acid radicals, which is useful for photoresist and photoengraving applications.

It is another object of this invention to provide a photosensitive polymer having a high sensitivity, good resolving power, good aging stability, good heat resistance, good adhesiveness and good etchant resistance.

These and other objects of this invention can be attained by providing a photosensitive composition containing a polymer having the radical as shown in the general formula:

wherein X and Y represent, respectively, hydrogen or halogen atoms or cyano or nitro radicals; Ar represents an aryl radical or a substituted aryl radical; and n represents an integer of from l-2; which is obtained by react ing a corresponding polymer having an active halogen atom with a salt of an a,/3-unsaturated carboxylic acid having the general formula of:

wherein the definitions of X, Y, Ar and n are respectively mentioned above.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS The photosensitive polymer of this invention can be obtained by reacting a polymer containing an active halogen atom with a salt of an u,;3-unsaturated carboxylic acid, having the above formula (II).

Suitable polymers which contain an active halogen atom include preferably the halogen containing polyethers prepared by polymerizing a halocyclic ether, such as epichlorohydrin, epibromohydrin, 1,2-dichloro-3,4-epoxybutane, 1,1-dichloro 1,3 epoxypropane, 3,3-bis(chloromethyl) oxetane or 3,3-bis(bromomethyl)oxetane. These polymers are soft, oil resistant, ozone resistant, and have a high degree of adhesiveness.

These polymers may also be formed by copolymerizing and halocyclic ether with an alkyleneoxide, e.g., ethyleneoxide, propyleneoxide, or butyleneoxide; an epoxyether, e.g., methylglycidylether, or phenylglycidylether; an oxetane (trimethyleneoxide), e.g., oxetane, 3-methyloxetane, or 3,3-dimethyloxetane, or an epoxy compound, e.g., styreneoxide.

The polymer containing the active halogen atom, in addition to the above polyethers may also be such polymers as polyvinylchloride, copolymers of vinylchloridevinylacetate: polymers of halogenoalkylvinylethers, e.g., B- chloroethyl-vinylether. The halogen content of the polymer is not particularly limited; however, it is preferably between 20-70 wt. percent.

Suitable 0:,B-lll1S2ltllfflt6d carboxylic acids of the general formula (11) include, for example, cinnamic acid, 4- phenyl 1,3-butadienecarboxylic acid, B-nitrophenylvinylcarboxylic acid, and fl-phenyl m-cyanovinylcarboxylic acid. These unsaturated carboxylic acids are reacted in the form of inorganic salts or organic amine salts. The desirable salts include the alkali metal salts, e.g., sodium, potassium, and lithium salts, and the quaternary ammonium salts, e.g., tetramethylammonium salt and trimethylbenzylammonium salt. Especially preferable is the use of the trimethylbenzylammonium salts and tetraethylammonium salts in order to provide a high reaction velocity.

It is possible to use the salts of the unsaturated carboxylic acid per se, or to use a combination of the unsaturated carboxylic acid together with a base for forming the salt, in the reaction system.

The reaction is usually conducted in a polar solvent in an atmosphere of an inert gas, such as nitrogen. Suitable solvents are preferably the dipole aprotic solvents, such as dimethylformamide, dimethylacetoamide, dimethylsulfoxide, triamide hexamethylphosphate, acetonitrile, and nitrobenzene. The temperature of the reaction is not limited, but it should preferably be higher than 60 C. to obtain a polymer having a high number of 04,}3-UI1S3U1- rated carboxylic acid radicals. On the other hand, it is preferable that the reaction temperature be lower than 120 C. to prevent gel formation and undesirable coloring of the resulting polymer.

The reaction can be conducted without a catalyst; however, an organic base, such as an organic amine, e.g., pyridine; organic quaternary ammonium hydroxide, e.g., trimethylbenzylammonium hydroxide; organic quaternary ammonium salt, e.g., trimethylbenzylammonium chloride, can be used as the catalyst. The polymer can be recovered by precipitation in a non-solvent, such as methanol.

The resulting polymer has been found to contain the radicals shown in general formula (I) which partially or entirely replace the active halogen atoms in the starting polymer. Highest sensitivity and etchant resistance are Obtained when 40-80% of halogen atoms in the starting polymer are replaced with the unsaturated carboxylic acid radicals.

The photosensitive composition of this invention can be prepared by dissolving the photosensitive polymer in a solvent. Suitable solvents for this purpose include any of the organic solvents known for dissolving this general type of polymer, including chlorobenzene, trichloroethylene, tetrahydrofuran, dioxane, methylcellosolve, methylcellosolve acetate, methylethyl ketone, methylisobutyl ketone, dimethylformamide, dimethylsulfoxide, and mixtures thereof. Especially preferable is chlorobenzene. The solvent may' be used in a sufiicient amount to dissolve said polymer.

Any of a variety of conventional sensitizers can be used in the photosensitive compositions of this invention. Suitable sensitizers include, for example, the aromatic nitro compounds, e.g., trinitroaniline, nitronaphthalene, S-nitroacenaphthene, 2-nitrofluorene, picramide; the ketones, e.g., benzophenone, Michlers ketone; the quinones, e.g., naphthoquinone, anthraquinone, 2,3-diphenylanthraquinone; the anthrones, e.g., benzathrone and pyrylium salts. When the photosensitive composition is used as a photoresist, it is preferable to use S-nitroacenaphthene, picramide, or benzanthrone as the photosensitizer. The quantity of sensitizer to use is usually 0.ll% by weight based on the weight of the photosensitive polymer.

Conventional stabilizers, e.g., hydroquinone, t-butylcatechol; plasticizers, e.g., triazene, triethyleneglycol dipropionate and various dyes or pigments, may be added to the photosensitive composition depending upon the I particular application. 7

The photosensitive compositions of this invention can be used in the form of films or can be used by coating onto a support, which can be metal, plastic, glass or paper, etc. The photosensitive compositions of this invention have the excellent properties of high sensitivity, good resolving power, good acid resistance, and good heat stability, as shown in the following examples. Accordingly, these materials can be widely used as photosensitive materials in a variety of applications. For example, they may be used as photoresists for preparation of printed circuits, for preparation of IC, for chemical milling, for printing plates for relief printing and intaglio processes and for photoprinting plates. They are especially effective for use in the preparation of IC by projection exposure methods, since the composition has high sensitivity and 4 is less effected by air than conventional compositions. The photosensitive composition can be also used for the preparation of printing plates by photo-engraving, used in lithograph or screen printing, or for the preparation of relief images. Moreover, they may be used for the preparation of copy and microfilm.

Having generally described the invention, a further understanding can be obtained by reference to certainspecific examples which are provided herein for purposes of illustration only and are not intended to be limiting unless otherwise specified.

EXAMPLE 1 Preparation of the polymer 2.8 g. of polyepichlorohydrin, having a reduced viscosity 1 sp./c.=2.03 (0.1 g./dl. benzene s01. 30 C.) (manufactured by Nippon Zeon Co., Ltd.) was mixed with 70 m1. of dimethylformamide (hereinafter referred to as DMF), and was dissolved by heating in an atmosphere of nitrogen gas. 1

7.7 g. of sodium cinnamate, suspended in 50 ml. of DMF, was,added to said solution. 1.1. g. of. benzyltrimethyl ammonium chloride was further added to said mixture as a catalyst and the mixture was reacted at 110 C. for 4 hours in a dark room. (All of the reactions hereinafter stated were conducted in an atmosphere of nitrogen gas in a dark room.) The resulting solution was washed several times with methanol and then with water, and the product was dissolved in THF, and was purified by reprecipitation with methanol. 4.03 g. of white polymer was obtained by drying under reduced pressure.

The infrared spectrum and elementary analysis of the resulting polymer showed that 56% of the chlorine atoms of the polyepichlorohydrin was replaced with cinnamic acid radicals. (Hereinafter, the rate of replacement of cinnamic acid radical is referred to as cinnamic acid conversion.) This reaction and purification were repeated, Without the use of benzyltrimethyl ammonium chloride as a catalyst. A white rubberlike polymer, having 19% of cinnamic acid conversion, was obtained.

EXAMPLE 2 Preparation of polymer .trimethylbenzyl ammonium hydroxide was added thereto and heated. The water resulting from the neutralization reaction, benzene and methanol, were distilled to obtain trimethylbenzyl ammonium cinnamate. The trimethylbenzyl ammonium cinnamate was mixed with the DMF solution of polyepichlorohydrin and reacted at C. for 2.5 hours in an atmosphere of nitrogen gas. The resulting product was purified similarly as described in Example 1, to yield.4.7 g. of a polymer having a 44% cinnamic acid conversion.

EXAMPLE 3 Preparation of polymer The process of Example 2 was repeated, using the same conditions except that the reaction time was 5.5 hours. A white polymer, having 63% cinnamic acid conversion, was obtained.

EXAMPLES 4-8 Preparation of polymer The process of Example 2 was repeated using the same conditions, except polyepichlorohydrin having a reduced A white rubber-like polymer, having a 60% cinnamic acid conversion, was obtained.

EXAMPLES 14-16 Preparation of polymer 5 viscosity 1; sp./c. =3.3 (0.1 g./dl. benzene sol. 30 C.) was 12 8 g. of polyeplchlorohydnn, as used in Example 1, useddalid 1 ii i i g f respectlvely changed as was dissolved in 50 ml. of DMF. Suspension solutions of State m e 0 owmg a the following salts in 50 ml. of DMF were respectively Cinnamic acid added to the polyepichlorohydrin solution, and reacted at Reaction time conversion 10 110 C. for 5 hours. I

(hour) (p Polymers having the following cinnamic acid conversions were obtained:

0.5 9 1.0 2.0 24 3.0 33 15 5.0 46 Cinnamic Salt of Amount of x rgrg rl EXAMPLE 9 Example acid salt (g.) (percent) Preparation of polymer 14 14 13.4 50 15 15 12.6 21 0.92 g. of polyepichlorohydrin, having a reduced vls- 16 cosity 7 P- l benzene a llktrirnethylbenzyl ammonium salt ofB-nitrophenylvinylcarboxylic completely dissolved in 33 m of DMF. 1.93 g. o cmnamlc ac acid and 19.3 g. of a 10% aqueous solution of tetraethyl- ,..Z;, momum Salt of B phenylflyanmnyl ammonium hydroxide were di l d i 50 1 f ha ;d16trimethylbenzyl ammonium salt of l-pheuyl-butadiene carboxylie anol, and methanol and water were completely removed c by distillation. The DMF solution of polyepichlorohydrin EXAMPLES 1749 was added to the resulting product, and was reacted at 110 C. for 5 hours in an atmosphere of nitrogen gas, in Preparafion of P y the abence P g of Whlte PQ havmg a Each of the following halogen containing polymers was 98% cmnamlc acld conversion: was obtameddissolved in ml. of DMF. A suspension solution of 11.6 EXAMPLE 10 g. of trimethylbenzyl ammonium cinnamate in 50 ml. of

DMF, was added to said polymer solution, and reacted ac- Preparatlon of Polymer cording to the conditions stated in the table. A polymer 2.8 g. of copolymer of propyleneoxide and epichloro- 5 having the following cinnamic acid conversion was obhydrin, 7.3 g. of potassium cinnamate and 2.5 g. of 40% tained:

Reaction condi- Polymer tions Clnnamie acid con- .Amount Temp. Time version Example Type (g.) 0.) (hr.) (percent) 17 Polyvinylchloride 1.9 5 a0 18 Copolymer of vinylchloride and 2. 2 60 5 20 vinylacetate. 19 PolyQfl-chloroethyl vinylether) 3. 2 110 5 methanol solution of trimethylbenzyl ammonium hydrox- EXAMPLE 20 ide were added to 100 ml. of DMF and were reacted at Th polymer f E l 1 a di olved i DMF and fOf 5 11011I$- The P y having a cinnamlc was coated onto a sheet of glass and was dried. The coated acid conversion was obtainedsheet of glass was exposed for 5 seconds by using a mer- E AMPLE 11 cury lamp (manufactured by Ushio Denk1 K.K. under trade name of Unipalse UM-30l) from a distance of 40 Pfepalatlon of Polymer cm. to obtain a solvent insoluble-acid resistant film. 2.8 g. of polyepichlorohydrin, as used in Example 1, EXAMPLE 21 of Sodium cinnamate, and PYfldlne, as a A photosensitive composition was prepared by dissolvy were mlXed, and were added to 1111- Of DMF, j 55 ing 1 g. of the polymer of Example 3 in a solvent mixture were reacted at 110 C. for 4 hours. The p y havlng of 10 ml. of tetrahydrofuran and 30 ml. of xylene. The a 50% clnnamlC acld collversloll was Obtalnedmixture was coated onto a quartz plate (4.5 x 10 cm.) by a rotary coater to provide a thin film. The solvent was re- EXAMPLE 12 moved by vacuum drying at 70 C. for 10 minutes, and a P f l 0 negative film for a photosensitive plate, was placed on reparation 0 p0 ymer the plate, and was exposed for 10 minutes by a mercury 2.8 g. of polyepichlorohydrin, as used in Example 1, lamp from a distance of 60 cm. After exposure, the unex 6,4 g, of ammonium innamate, 2.5 g, of methanol soluposed parts were dissolved with trichloroethylene to obtion of trimethylbenzyl ammonium hydroxide, as a catatain a clear image. lyst, and 100 ml. of DMF, were mixed and were reacted 65 EXAMPLE 22 at 110 C. for 5 hours. 2. g; of F White l'll'bbeflike 0.5%, based on the weight of polymer of a sensitizer, P 3 havlng a 15% 613112111116 acld COHVBTSIOB, was S-nitroacenaphthene, was added to the photosensitive comobtained. position prepared in Example 22. The composition was EXAMPLE 13 coated on a sheet of glass and was exposed for 3 seconds Pm aration of 01 met 70 at a distance of 125 cm., in accordance with the process P y I of Example 20. The sensitivity was measured by use of of P Y P 'P Y of Potasslum 9 Step tablet No. 2, manufactured by Eastman Kodak Co., namate, 1.0 g. of trimethylbenzyl ammonium bromide, as a catalyst, and Of e mixed, and Were It was found that the film was cross-linked and insolureacted at C. for 5 hours. 75 ble to 8 steps. The results show that the film has 61 times 7 8 the sensitivity of commercial KPR (polyvinylcinnamate Time for image deformation, min. manufactured by Eastman Kodak Co., Ltd.).

Example 31 No deformation after 90 minutes. EXAMPLES 23-28 R f A photosensitive composition was prepared in accord- KPR 19. ance with the process of Example 21 by use of the follow- KTFR 36. ing polymer, and the sensitivity was measured. KMER 75.

Conditions of exposure Specific Distance Time sensitiv- Example Polymer Sensltizor (cm.) (see) ity Example 2 None 60 5 40. 5 Examplefi o 60 90 3.0 Example 6 60 60 9. 0 Example7 60 60 13 Example 8 60 60 25 Polyvinylcinnam 64 60 1 l 8 fi-nitroacenaph- 128 1.1 97,000

thene (10%). Ref KPR Some sensitizer-... 58 30 100 In Examples 24-27, the composition was coated onto a sheet of glass and was exposed from the rear. As shown in the above table, the photosensitive compositions of th1s invention have a high sensitivity, even though a sensitizer is not added. When a sensitizer is added, the sensitivity increases to several hundred times that of commercial prod ucts.

EXAMPLE 29 The photosensitive composition, prepared as in Example 22, was filtered and the filtrate was rotary-coated onto an aluminum metallized surface of a sheet of glass, and was dried at 70 C. for 10 minutes. A resolving power test chart was placed on the surface and was exposed for 3 seconds of a distance of 125 cm. by the mercury lamp. In accordance with the process of Example 21, the sheet was treated and the resolving power was measured by a microscope. A line having 2a of width was completely and clearly reproduced.

EXAMPLE 30 The photosensitive composition prepared in accordance with Example 28 was coated onto a sheet of glass and was dried, and exposed for 1.1 seconds by the mercury lamp at a distance of 128 cm. The sheet was immersed in 46% hydrofluoric acid and the time required for strip-off was measured. As a reference, the same measurement was made for the commercial products of KPR, KME-R and KTFP which are cyclic rubber containing azide compounds manufactured by Eastman Kodak Co., Ltd.

Time required for strip-off Example 30 No strip-off after 30 minutes.

Reference:

KPR 2.2. KMER 26. KTFR 26.

EXAMPLE 31 A photosensitive composition was prepared in accordance with the process of Example 22 by using the polymer of Example 2. The composition was coated onto an aluminum metallized surface of a sheet of glass, and a negative film was placed on the sheet and was exposed and treated in accordance with the process of Example 22 to form an image.

The product was heated at 150 C. in vacuum for minutes, and cooled, and was immersed in a corrosive solution mixture of 41% ammonium fluoride and 46% hydrofluoric acid at a volume ratio of 6:1. The time required for image deformation was measured.

As shown in Examples 30 and 31, the composition of this invention has a high degree of resistance, as a photoresist, against a corrosive solution, such as hydrofluoric acid.

EXAMPLE 32 A photosensitive composition was prepared in accordance with the process of Example 21 by using the polymer of Example 9. The composition was coated onto an aluminum foil which was sand-blasted and washed. The coated foil was dried, exposed and developed to obtain a clear image.

EXAMPLE 33 The photosensitive composition prepared in accordance with Example 22 was coated onto a silicon wafer covered with an oxidized film, and was made uniform by use of a spinner (4000 r.p.m./2 minutes). The product was prebaked for 20 minutes in a drier, and was exposed for 3 minutes through a mask for IC by the mercury lamp, and was treated in accordance with the process of Example 21. The product was post-baked at C. for 20 minutes and etched by the use of corrosive hydrofluoric acid by immersion. As a result, a satisfactory pattern of circuits was observed by a microscope.

EXAMPLE 34 The photosensitive composition prepared in accordance with Example 23 was coated onto a cleaned plate for printed circuitry. The coated plate was dried and exposed for 3 seconds under covering with an original negative film, and was developed and dried in accordance with the process of Example 21 to obtain a relief image on the printed circuit plate. A satisfactory printed circuit plate was obtained by etching with an aqueous solution of ferric chloride.

EXAMPLE 35 The photosensitive composition, prepared in accordance with Example 22, was coated on an aluminum plate, which was sand-blasted. The coated plate was dried and exposed through a negative film, and was developed in accordance with the process of Example 21, to prepare a lithographic printing plate. A clear printed matter was obtained in a conventional method with a lithographic printing machine by the use of the resulting printing plate.

EXAMPLE 36 The photosensitive composition was coated on a cleaned zinc plate and was dried, exposed, developed in accordance with the process of Example 35, and was heated at 150 C. for 3 minutes and was treated with a Dowetchant to obtain the printing plate for relief printing.

Having now fully described the invention, it will be ap-' parent to one of ordinary skill in the art that many changes and modifications can be made thereto without departing from the spirit and scope of the invention as set forth in the appended Claims.

What is claimed as new and desired to be secured by Letters Patent of the United States is:

1. In a process for preparing a photosensitive polymer having at least one radical shown by the formula:

wherein X and Y, respectively, represent a hydrogen or halogen atom, or a cyano or nitro radical, Ar represents an aryl radical; and n represents an integer from 1-2; the improvement which comprises reacting a polymer containing at least one active halogen atom with a quaternary ammonium salt of an u,p-unsaturated carboxylic acid having the formula:

10 from the group consisting of alkyleneoxides, epoxyethers, and oxetanes; polyvinylchloride, copolymer of vinylchloride-vinylacetate, and polymers of halogenoalkylvinylethers.

4. The process of Claim 1, wherein the quaternary ammonium salt is of a member selected from the group consisting of cinnamic acid, 4-phenyl-1,3-butadiene carboxylic acid, p-nitrophenylvinyl carboxylic acid, fl-phenyla-cyanovinyl carboxylic acid.

5. The process of Claim 4, wherein the quaternary ammonium salt is tetramethyl ammonium salt, trimethylbenzylammonium salt or tetraethylammonium salt.

References Cited UNITED STATES PATENTS 2,725,372 11/1955 Minsk 260-91.3 2,732,301 1/1956 Robertson et al. -7 3,409,593 11/ 19 68 Messwarb et al. 260-47 3,694,383 9/1972 Azami et al 260-2 X A OTHER REFERENCES Chem. Abstracts 56, 3650d (1962). Chem. Abstracts 61, 8435b (1964).

WILLIAM H. SHORT, Primary Examiner E. A. NIELSEN, Assistant Examiner US. Cl. X.R.

96-351, R; 204159.14; 260-30.8 DS, 30.4 EP, 31.4 EP, 32.6 R, 33.8 EP, 87.1, 92.8 A, 476 R 

